Characterisation of microneedle replication and flow behaviour in ultrasonic micro-injection moulding through design of experiments

This research investigates the impact of process parameters on ultrasonic micro-injection moulding (u-μIM) by studying microneedle replication efficiency, temperature evolution during moulding, melt flow consistency and sonication behaviour. The experimentation comprises of a full-factorial design of experiments using three process variables: sonication time, mould temperature and injection force. The current study presents that; (i) mould temperature was found to be the most influential parameter to tune and optimise micro-feature replication, (ii) consistent ultrasonic micromoulding flows can be achieved using higher mould temperatures, (iii) injection force is a key parameter influencing sonication frequency, a critical aspect of the ultrasonic method to obtain a repeatable manufacturing process. These outcomes will be a datum during development of the manufacturing processes for specific products using the ultrasonic method. The research presented here takes a unique approach to characterise the ultrasonic method for the development of this novel technique, particularly for microneedle patch and medical device production. With this increased level of understanding of u-μIM process characteristics, the method can become an energy efficient and cost-effective alternative to conventional micro-injection moulding processes for delivering high-quality, miniature components

Mechanical durability of hydrophobic surfaces fabricated by injection moulding of laser-induced textures

YesThe paper reports an investigation on the mechanical durability of textured thermoplastic surfaces together with their respective wetting properties. A range of laser-induced topographies with different aspect ratios from micro to nanoscale were fabricated on tool steel inserts using an ultrashort pulsed near infrared laser. Then, through micro-injection moulding the topographies were replicated onto polypropylene surfaces and their durability was studied systematically. In particular, the evolution of topographies on textured thermoplastic surfaces together with their wetting properties were investigated after undergoing a controlled mechanical abrasion, i.e. reciprocating dry and wet cleaning cycles. The obtained empirical data was used both to study the effects of cleaning cycles and also to identify cleaning procedures with a minimal impact on textured thermoplastic surfaces and their respective wetting properties. In addition, the use of 3D areal parameters that are standardised and could be obtained readily with any state-of-the-art surface characterisation system are discussed for monitoring the surfaces' functional response.European Commission H2020 ITN programme “European ESRs Network on Short Pulsed Laser Micro/Nanostructuring of Surfaces for Improved Functional Applications” (Laser4Fun) under the Marie Skłodowska-Curie grant agreement No. 675063 (www.laser4fun.eu) and the UKIERI DST programme “Surface functionalisation for food, packaging, and healthcare applications”. In addition, the work was supported by three other H2020 programmes, i.e. the projects on “Modular laser based additive manufacturing platform for large scale industrial applications” (MAESTRO), “High-Impact Injection Moulding Platform for mass-production of 3D and/or large micro-structured surfaces with Antimicrobial, Self-cleaning, Anti-scratch, Anti-squeak and Aesthetic functionalities” (HIMALAIA) and “Process Fingerprint for Zero-defect Net-shape Micromanufacturing” (MICROMAN)

Rapid tooling : investigation of soft-tooled micro-injection moulding process characteristics using in-line measurements and surface metrology

Purpose The purpose of this study is to demonstrate and characterise a soft-tooled micro-injection moulding process through in-line measurements and surface metrology using a data-intensive approach. Design/methodology/approach A soft tool for a demonstrator product that mimics the main features of miniature components in medical devices and microsystem components has been designed and fabricated using material jetting technique. The soft tool was then integrated into a mould assembly on the micro-injection moulding machine, and mouldings were made. Sensor and data acquisition devices including thermal imaging and injection pressure sensing have been set up to collect data for each of the prototypes. Off-line dimensional characterisation of the parts and the soft tool have also been carried out to quantify the prototype quality and dimensional changes on the soft tool after the manufacturing cycles. Findings The data collection and analysis methods presented here enable the evaluation of the quality of the moulded parts in real-time from in-line measurements. Importantly, it is demonstrated that soft-tool surface temperature difference values can be used as reliable indicators for moulding quality. Reduction in the total volume of the soft-tool moulding cavity was detected and quantified up to 100 cycles. Data collected from in-line monitoring was also used for filling assessment of the soft-tool moulding cavity, providing about 90% accuracy in filling prediction with relatively modest sensors and monitoring technologies. Originality/value This work presents a data-intensive approach for the characterisation of soft-tooled micro-injection moulding processes for the first time. The overall results of this study show that the product-focussed data-rich approach presented here proved to be an essential and useful way of exploiting additive manufacturing technologies for soft-tooled rapid prototyping and new product introduction

Lotus-leaf inspired surfaces: hydrophobicity evolution of replicas due to mechanical cleaning and mold wear

YesInspired from the low wetting properties of Lotus leaves, the fabrication of dual micro/nano-scale topographies is of interest to many applications. In this research, superhydrophobic surfaces are fabricated by a process chain combining ultrashort pulsed laser texturing of steel inserts and injection moulding to produce textured polypropylene parts. This manufacturing route is very promising and could be economically viable for mass production of polymeric parts with superhydrophobic properties. However, surface damages, such as wear and abrasion phenomena, can be detrimental to the attractive wetting properties of replicated textured surfaces. Therefore, the final product lifespan is investigated by employing mechanical cleaning of textured polypropylene surfaces with multipurpose cloths following the ASTM D3450 standard. Secondly, the surface damage of replication masters after 350 injection moulding cycles with glass-fiber reinforced polypropylene, especially to intensify mould wear, was investigated. In both cases, the degradation of the dual-scale surface textures had a clear impact on surface topography of the replicas and thus on their wetting properties, too.Europe Union H2020 research and innovation programme

Effects of mould wear on hydrophobic polymer surfaces replicated using plasma treated and laser-textured stainless steel inserts

YesThe mass production of polymeric parts with functional surfaces requires economically viable manufacturing routes. Injection moulding is a very attractive option however wear and surface damage can be detrimental to the lifespan of replication masters. In this research, the replication of superhydrophobic surfaces is investigated by employing a process chain that integrates surface hardening, laser texturing and injection moulding. Austenitic stainless steel inserts were hardened by low temperature plasma carburising and three different micro and nano scale surface textures were laser fabricated, i.e. submicron triangular LaserInduced Periodic Surface Structures (LIPSS), micro grooves and Lotus-leaf like topographies. Then, a commonly available talc-loaded polypropylene was used to produce 5000 replicas to investigate the evolution of surface textures on both inserts and replicas together with their functional response. Any wear orsurface damage progressively built up on the inserts during the injection moulding process had a clear impact on surface roughness and peak-to-peak topographies of the replicas. In general, the polymer replicas produced with the carburised inserts retained the wetting properties of their textured surfaces for longer periods compared with those produced with untreated replication masters.European Union’s H2020 research and innovation programme under the Marie Skłodowska-Curie grant agreement No. 675063 (www.laser4fun.eu). The work was also supported by three other H2020 projects, i.e. “HighImpact Injection Moulding Platform for mass-production of 3D and/or large micro-structured surfaces with Antimicrobial, Self-cleaning, Anti-scratch, Anti-squeak and Aesthetic functionalities” (HIMALAIA, No. 766871), “Process Fingerprint for Zero-defect Net-shape Micromanufacturing” (MICROMAN, No. 674801) and “Modular laser based additive manufacturing platform for large scale industrial applications” (MAESTRO, No. 723826). Further support was provided by the UKIERI DST programme “Surface functionalisation for 18/20 Accepted in the journal Tribology – Materials, Surfaces & Interfaces. food, packaging, and healthcare applications

Correlating nano-scale surface replication accuracy and cavity temperature in micro-injection moulding using in-line process control and high-speed thermal imaging

YesMicro-injection moulding (μIM) stands out as preferable technology to enable the mass production of polymeric components with micro- and nano-structured surfaces. One of the major challenges of these processes is related to the quality assurance of the manufactured surfaces: the time needed to perform accurate 3D surface acquisitions is typically much longer than a single moulding cycle, thus making impossible to integrate in-line measurements in the process chain. In this work, the authors proposed a novel solution to this problem by defining a process monitoring strategy aiming at linking sensitive in-line monitored process variables with the replication quality. A nano-structured surface for antibacterial applications was manufactured on a metal insert by laser structuring and replicated using two different polymers, polyoxymethylene (POM) and polycarbonate (PC). The replication accuracy was determined using a laser scanning confocal microscope and its dependence on the variation of the main μIM parameters was studied using a Design of Experiments (DoE) experimental approach. During each process cycle, the temperature distribution of the polymer inside the cavity was measured using a high-speed infrared camera by means of a sapphire window mounted in the movable plate of the mould. The temperature measurements showed a high level of correlation with the replication performance of the μIM process, thus providing a fast and effective way to control the quality of the moulded surfaces in-line.MICROMAN project (“Process Fingerprint for Zero-defect Net-shape MICRO MANufacturing”, http://www.microman.mek.dtu.dk/) - H2020 (Project ID: 674801), H2020 agreement No. 766871 (HIMALAIA), H2020 ITN Laser4Fun (agreement No. 675063

X-ray computed tomography for predictive quality assessment, 3D visualisation of micro-injection mouldings and soft-tool deformation

This work presents X-ray computed tomography (XCT) as a dimensional quality assurance technique for micro-injection moulded polymeric test objects for the establishment of predictive quality models and quantifying soft-tool deformation. The results are compared against an industry standard laser-scanning-confocal microscope (LSCM) for the evaluation of XCT’s capability. The work demonstrates; (i) the exploitation of a XCT equipment for dimensional characterisation of micro-injection moulded products made out of polymers with adequate acquisition times, (ii) that acquired XCT data from the 3D visualisation of the micromouldings perform on par with a laser-scanning-confocal microscope in a quality prediction model, (iii) that the deformation occurring in an additively manufactured soft-tool can be quantified using XCT. The technique was particularly superior in volumetric data acquisition compared to LSCM in the filling prediction of the micromouldings. Better accuracy and repeatability in predicting the quality of the mouldings up to 92% achieved with XCT, in conjunction with an in-line collected soft-tool surface temperature data as an indirect quality assurance method. Given the capability of the XCT for the 3D data acquisition of polymeric miniature components, the approach described here has great potential in high-value micro-manufacturing process quality modelling for in-line quality assessment of miniature and added value products in data-rich contexts

A cost-effective process chain for thermoplastic microneedle manufacture combining laser micro-machining and micro-injection moulding

YesHigh-throughput manufacturing of transdermal microneedle arrays poses a significant challenge due to the high precision and number of features that need to be produced and the requirement of multi-step processing methods for achieving challenging micro-features. To address this challenge, we report a flexible and cost-effective process chain for transdermal microneedle array manufacture that includes mould production using laser machining and replication of thermoplastic microneedles via micro-injection moulding (micromoulding). The process chain also incorporates an in-line manufacturing data monitoring capability where the variability in the quality of microneedle arrays can be determined in a production run using captured data. Optical imaging and machine vision technologies are also implemented to create a quality inspection system that allows rapid evaluation of key quality indicators. The work presents the capability of laser machining as a cost-effective method for making microneedle moulds and micro-injection moulding of thermoplastic microneedle arrays as a highly-suitable manufacturing technique for large-scale production with low marginal cost.This research work was undertaken in the context of MICRO-MAN project (“Process Fingerprint for Zero-defect Net-shapeMICROMANufacturing”, http://www.microman.mek.dtu.dk/).MICROMAN is a European Training Network supported byHorizon 2020, the EU Framework Programme for Research andInnovation (Project ID: 674801). This research has also receivedfunding and support from two other Horizon 2020 projects:HIMALAIA (Grant agreement No. 766871) and Laser4Fun (GA no.675063)

Ultrasonic micromoulding: Process characterisation using extensive in-line monitoring for micro-scaled products

YesIndustry-standard quality management systems such as Six Sigma and emerging Industry 4.0 compliant production processes demonstrate the importance of in-line condition monitoring of manufacturing methods for achieving the highest levels of product quality. Measurement data collected as the process is running can inform the operator about unexpected changes in machine operation or raw materials that could negatively impact production; and offer an opportunity for a process control intervention to stabilise production. However, micro-manufacturing production lines can pose a challenging environment for deploying such systems, since processing events can occur extremely rapidly and in harsh environments. Moreover, the small scale of micro-nano featured components can make sensor installation even more problematic. Recently, ultrasonic micromoulding has drawn attention in niche markets due to its unique advantages for processing thermoplastics as a new micro-manufacturing technology. The process differs from conventional moulding significantly by eliminating the need for a plasticising screw and using direct application of ultrasonic energy to melt the polymer. This offers numerous benefits such as decrease in energy usage, moulding at lower pressures, easier cleaning, and reduced material residence times, the latter which could be beneficial for pharma-grade polymers or polymers with active ingredients. However, very little work has been reported attempting to monitor the process using in-line measurements. This work aims to evaluate the characteristics of the ultrasonic micromoulding process for microinjection moulding of a microneedle array using a range of sensor technologies including: data recorded by the machine controller; a high-speed thermal camera and a cavity pressure transducer. The data has captured the highly dynamic process environment with a high degree of accuracy. The relationship between the process data and dimensional quality of the ultrasonically micromoulded products has been quantified and subsequently implemented as a cost-effective in-line quality assurance method.Horizon 2020, the EU Framework Programme for Research and Innovation (Project ID: 674801). This research has also received funding and support from two other Horizon 2020 projects: HIMALAIA (Grant agreement No. 766871) and Laser4Fun (GA no. 675063)The full-text of this article will be released for public view at the end of the publisher embargo on 20 Aug 2022